General 220 Restoration Questions

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FLBoyKDX220
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General 220 Restoration Questions

Post by FLBoyKDX220 » 03:55 pm Aug 10 2019

Im working on getting my new purchase of a worn out 220 back on the trail and have a few questions.

1) I got the new clutch / springs installed and have yet to torque the clutch hub nut to 65 LBS. Does anyone have a do it yourself hack to hold the flywheel? Service manual part # for that tool is nearly $300. I tried a large rubber belt type oil filter wrench and it wont hold it.

2) The attached pic: I stuck the red plug on the open nipple for now. Nothing was attached and I cant seem to find a diagram that says what it is. I am assuming its the trans case breather? What should go there? A hose dumping to the ground?

Bike ran when I bought it a few weeks ago but very rich. bufftester recommended a new piston which is on the list but way down for now. I just want to ride it briefly and know that Im not throwing money down the drain. So far, new chain & sprockets, new air filter (old 1 was gummy), new gas, new clutch & cable and exhaust o rings when I can get it back together. Previous owner put new tires on it and included an eBay PWK 38 carb in the box. I think Ill clean & try the stock carb for now.

Any advice appreciated!
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kdxsully
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Re: General 220 Restoration Questions

Post by kdxsully » 04:39 pm Aug 10 2019

FLBoyKDX220 wrote:
03:55 pm Aug 10 2019
Im working on getting my new purchase of a worn out 220 back on the trail and have a few questions.

1) I got the new clutch / springs installed and have yet to torque the clutch hub nut to 65 LBS. Does anyone have a do it yourself hack to hold the flywheel? Service manual part # for that tool is nearly $300. I tried a large rubber belt type oil filter wrench and it wont hold it.

2) The attached pic: I stuck the red plug on the open nipple for now. Nothing was attached and I cant seem to find a diagram that says what it is. I am assuming its the trans case breather? What should go there? A hose dumping to the ground?

Bike ran when I bought it a few weeks ago but very rich. bufftester recommended a new piston which is on the list but way down for now. I just want to ride it briefly and know that Im not throwing money down the drain. So far, new chain & sprockets, new air filter (old 1 was gummy), new gas, new clutch & cable and exhaust o rings when I can get it back together. Previous owner put new tires on it and included an eBay PWK 38 carb in the box. I think Ill clean & try the stock carb for now.

Any advice appreciated!
1. A lot of people use a penny between the primary gear and the clutch gearing. This works because copper is a softer metal than the gears, but use your common sense. Don’t crank it.

2. Usually a plastic 90 degree elbow and a hose going down. Try Lowe’s for one that will fit. Or eBay search the part number. Use the parts diagrams on partzilla.

3. Make sure that PWK eBay carb is genuine. A lot of crappy Chinese copies out there and they’ll run like garbage. It should have a serial number.
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bufftester
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Re: General 220 Restoration Questions

Post by bufftester » 05:02 pm Aug 10 2019

1. Put the chain on, put it in gear and put a breaker bar or long screwdriver through a hole in the sprocket and brake disc to hold it in place against the swing arm, or the penny trick.

2. p/n 92190-1007 tube, about 30$, or any rubber hose the correct diameter to fit, run it up to the airbox, theres a hole near the top it passes through

3. Ditto on the ebay carb. Search the internet for how to identify real vs clone. The clones NEVER owrk...NEVER...just ask us how we know here :grin: lol. Clean the stock one, but DON'T dip it (Berrymans, etc) or you will destroy the jet block gasket and have to buy another part :? Write down the pilot and main jet sizes and the needle clip position. Thorough clean and blow out all the passages with air. Lots of posts on here about carb cleaning and setting float height.

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Re: General 220 Restoration Questions

Post by ericr » 05:05 pm Aug 10 2019

1. There's a couple ways to tighten the clutch nut. I remove the clutch spring holder (pn 13091A in the image) and then put fender washers on the clutch spring bolts. Just snug them down on the springs and you'll lock up the clutch. I then put a penny between the clutch gear and the crank gear and torque away. Another way is to use a piston lock up tool that threads into the spark plug hole. I use this when working with the flywheel.
clutch spring holder.JPG
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2. The transmission breather has a rubber hose leading to a hole in the airbox. In the photo below, you can see the location of the hose above the air filter.
breather hose.JPG
breather hose.JPG (25.76 KiB) Viewed 376 times
'02 KDX 200, '02 KDX 220 - My restoration thread... viewtopic.php?f=77&t=22266

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Re: General 220 Restoration Questions

Post by pumpguy » 06:24 pm Aug 10 2019

For holding the flywheel, a Vice Grip #20R chain pliers / clamp is my go to tool. This is very useful for holding large diameter or odd shaped parts.

Using a holder like this avoids putting all the load on just one gear tooth.

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Re: General 220 Restoration Questions

Post by FLBoyKDX220 » 07:25 pm Aug 10 2019

I wondered what that hole was in the airbox! Great thanks.

Chain pliers sounds like another tool I need

And yeah the new carb has no #s on it. Just the Keihn PWK 38 label on the box. I thought the machining didn't look right so Its gotta be an imposter.

Thanks all, next time you hear from me she'll be running (hopefully)

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Re: General 220 Restoration Questions

Post by KDXGarage » 09:54 am Aug 11 2019

piston lock up tool works well

Hose definitely goes up into the airbox on 1986 and newer.

Check the homemade goop gasket carefully on the clutch cover. Stock is a paper gasket. No goop gaskets stock besides the case halves.
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Re: General 220 Restoration Questions

Post by kdxsully » 10:10 am Aug 11 2019

Wouldn’t a piston lockup tool put the load on your rod? That worries me a bit. Do they make universal gear holder tools? I know of the Kawasaki one
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Re: General 220 Restoration Questions

Post by KDXGarage » 11:14 am Aug 11 2019

Motion Pro makes one.

I would hate to waste a gasket on the flywheel side.
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Re: General 220 Restoration Questions

Post by kdxsully » 01:58 pm Aug 11 2019

KDXGarage wrote:
11:14 am Aug 11 2019
Motion Pro makes one.

I would hate to waste a gasket on the flywheel side.
Don’t tell my mom, but I reused mine.
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Re: General 220 Restoration Questions

Post by KDXGarage » 06:33 am Aug 12 2019

Good until it breaks?
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Re: General 220 Restoration Questions

Post by pumpguy » 06:48 pm Aug 12 2019

You don't need to buy or use a piston lock up tool.

Just feed a length of nylon rope through the spark plug hole and use that. Just be sure the piston is high enough up in the stroke first so all the ports are covered. You don't want that rope to get pinched by the piston in a port.

That said, I still prefer a flywheel holding tool like a Vice Grip chain pliers.

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Re: General 220 Restoration Questions

Post by kdxsully » 07:06 pm Aug 12 2019

KDXGarage wrote:
06:33 am Aug 12 2019
Good until it breaks?
Good until I know I won’t be going in there for a while.
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Re: General 220 Restoration Questions

Post by kdxsully » 07:07 pm Aug 12 2019

pumpguy wrote:
06:48 pm Aug 12 2019
You don't need to buy or use a piston lock up tool.

Just feed a length of nylon rope through the spark plug hole and use that. Just be sure the piston is high enough up in the stroke first so all the ports are covered. You don't want that rope to get pinched by the piston in a port.

That said, I still prefer a flywheel holding tool like a Vice Grip chain pliers.
I’ve seen someone use trimmer line.
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